Pre-shaped form construction components, system, and method of construction using the same

ABSTRACT

A building component includes a form that is pre-shaped. The form includes a channel segment, defined, at least in part, by a base region and a wall that extends from the base region. The form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment. The abutment is between the channel segment and the corresponding channel segment, and when respective ends of the respective base regions of the channel segment and the corresponding channel segment are in abutment, a beam channel is created between the form and the corresponding form. Further, when respective ends of the respective walls of the channel segment and the corresponding channel segment are in abutment, a column channel is created between the form and the corresponding form.

BACKGROUND Technical Field

This disclosure relates to pre-shaped forms as building components used for building construction. More particularly, the pre-shaped forms are pre-manufactured building components such as wall panels, column and beam structures, ceiling and floor panels, footing structures and panels, stair structures, and corner forms. These components provide for fast and efficient building erection, improved strength, durability, weight, and energy efficiency characteristics, and are highly customizable by craftsman of medium skill.

Related Art

Wall panel systems comprised primarily of concrete suffer from many inherent defects including: poor thermal characteristics, high costs to manufacture and install, poor fire and wind resistance, added weight stress requirements for a building's foundation, etc. In general, concrete wall panel systems rely solely on the panel and/or structural support members integrated therein for strength.

Attempts have been made in the industry to decrease the weight and improve the strength of the individual panels by adding metal studs or similar support members, and/or by using concrete material. While such reinforced conventional panels have some benefits, the metal studs provide poor insulative qualities in cold climates due to the high heat transfer associated with the metallic studs. Furthermore, embedded metallic studs and nails make onsite customization dangerous and difficult.

In other conventional modular panel systems, attempts have been made to create a lightweight building panel that withstands expected loads and provides high insulation characteristics. However, these conventional panels generally implement a plurality of metal and carbon components to construct, thus reducing or eliminating the ability to fully customize the panels on the jobsite due the challenges and inherent risks of cutting through such obstacles. Additionally, any onsite modifications could compromise the strength and integrity of the conventional panel systems, as the strength of the system is greatest when each panel remains intact as one cohesive unit. Furthermore, as the conventional panels are constructed primarily out of a lightweight insulative material, they lack the fire protection that a panel made mostly of a lightweight cementitious material offers. Therefore, having a panel system that is both customizable onsite while also providing a higher fire rating is desired.

Additionally, a primary aim of conventional panels has been to lower the cost of modular panel systems. However, due to the series of components that are required for each panel, the end result is a panel that still has relatively high manufacture costs. The high cost prevents most new building owners, especially in the residential market, from using the conventional panel systems. Thus, a strong, lightweight panel that is less expensive to manufacture and that is economical to construct in residential and commercial markets is desired by many in the construction industry.

It is contemplated that cellular concrete may be useful in construction. However, attempts using conventional methods are cost prohibitive and/or lack in structural strength. Cellular concrete has many names, but essentially the expression “cellular concrete” (often referred to as aerated concrete) denotes a material expanded further to the presence of small bubbles into the concrete mixture during its setting, which will confer porosity to the final cured material. Due the presence of the bubbles, cellular concrete is often considered to be “lightweight,” “enlightened,” “porous,” or “air-entrained,” in comparison to conventional concrete materials, i.e. the resulting cellular concrete material has a lower density than a conventional concrete material.

Some characteristics of cellular concrete with respect to its use as a building material include sound absorption, lightweight, insulative, and fire resistant.

There are two common methods for forming a structure of cellular concrete—autoclaved and non-autoclaved. Autoclaved aerated concrete (AAC) utilizes steam, pressure, and/or heat to cure the cellular concrete resulting in greater strength than the non-autoclaved method. However, the inherent costs in manufacturing using this method make it more expensive than many other building materials, including non-autoclaved cellular concrete. Furthermore, the AAC panels do not follow the innovative column and beam approach as outlined in this invention. The non-autoclaved method utilizes a foaming agent and other ingredients without baking the cellular concrete with heat and steam. This method is less expensive to manufacture but lacks the structural strength of AAC, and results in limitations to the size of the panel that can be used in construction—the basic size typically no larger than cement blocks. Some improvements have been made in increasing the strength of non-autoclaved cellular concrete by adding carbon fiber or even carbon nanotubes, among other compounds to the mix. However, a building material that combines the strength of AAC in the form of a highly customizable wall panel, while remaining less expensive to manufacture, is desired.

SUMMARY

This disclosure relates to a building component and a system of building components. The building components within a system may vary in shape, dimensions, and geometry. However, the building components all have in common the inclusion of an economically advantageous and geometrically-adaptable material. In an embodiment, the common material may include a lightweight cementious material. Using a combination of various components of varying geometries, it is contemplated that an entire building structure may be formed using the components of the system described herein.

In an embodiment, this disclosure describes a building component that may include a form that is pre-shaped and made of a lightweight cementious material. The form may have a channel segment that extends along at least a part of the form. A profile of the channel segment may be defined, at least in part, by a first portion that projects in a first direction and a second portion that projects in a second direction that is transverse to the first direction. The profile of the channel segment may be defined from a perspective of looking at the channel segment in line with a direction of extension of the channel segment. The form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment. The abutment may be between the channel segment and the corresponding channel segment such that a beam channel or a column channel is created between the form and the corresponding form. Note, for the purposes of this document, the term “beam” may refer generally to any horizontally-oriented reinforcing structure, the formation of which may occur in a beam channel (or channel segment) of building components. Further, the term “column” may refer generally to any vertically-oriented reinforcing structure, the formation which may occur in a column channel (or channel segment) of building components.

In another embodiment, this disclosure describes a building component that may include a form that is pre-shaped. The form may include a channel segment, defined, at least in part, by a base region and a wall that extends from the base region. The form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment. The abutment may be between the channel segment and the corresponding channel segment. When respective ends of the respective base regions of the channel segment and the corresponding channel segment are in abutment, a beam channel may be created between the form and the corresponding form. Alternatively, when respective ends of the respective walls of the channel segment and the corresponding channel segment are in abutment, a column channel may be created between the form and the corresponding form.

In another embodiment, this disclosure describes a method of constructing a building structure. The method may include an act of disposing a form in a position for constructing a portion of a structure. The form may be pre-shaped and made of a lightweight cementious material or a different non-cementious material. The form may include a channel segment, defined, at least in part, by a base region and a wall that extends from the base region. The method may further include an act of abutting a corresponding form having a corresponding channel segment against the form such that: the channel segment and the corresponding channel segment are aligned, and one of a beam channel or a column channel is created between the form and the corresponding form. Additionally, the method may include pouring a reinforced concrete mix into the one of the beam channel or the column channel such that the form and the corresponding form are a permanent fixture with the reinforced concrete.

BRIEF DESCRIPTION OF THE DRAWINGS

The Detailed Description is set forth with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items. Furthermore, the drawings may be considered as providing an approximate depiction of the relative sizes of the individual components within individual figures. However, the drawings are not to scale, and the relative sizes of the individual components, both within individual figures and between the different figures, may vary from what is depicted. In particular, some of the figures may depict components as a certain size or shape, while other figures may depict the same components on a larger scale or differently shaped for the sake of clarity.

FIG. 1A illustrates a perspective view of a wall panel form in a vertical orientation according to an embodiment of the instant application.

FIG. 1B illustrates a perspective view of a wall panel form in a horizontal orientation according to an embodiment of the instant application.

FIG. 2A illustrates a perspective view of a pair of abutting wall panel forms having concrete poured into a channel formed therebetween according to an embodiment of the instant application.

FIG. 2B illustrates a top cross-sectional view of a pair of abutting wall panel forms having a reinforced concrete column in a channel formed therebetween according to an embodiment of the instant application.

FIG. 3A illustrates a partial side profile view of a wall panel form according to an embodiment of the instant application.

FIG. 3B illustrates an alternative profile of a channel segment for a form according to an embodiment of the instant application.

FIG. 3C illustrates an alternative profile of a channel segment for a form according to an embodiment of the instant application.

FIG. 3D illustrates a partial cross-sectional view of a channel segment of a wall panel form having reinforcements according to an embodiment of the instant application.

FIG. 4A illustrates an end view of a panel form having an insulative core according to an embodiment of the instant application.

FIG. 4B illustrates an end view of a panel form having embedded reinforcements according to an embodiment of the instant application.

FIG. 4C illustrates an end view of a panel form having internal channels according to an embodiment of the instant application.

FIG. 5 illustrates a front view of a wall panel form having utility chases therein according to an embodiment of the instant application.

FIG. 6 illustrates a cross-sectional view of an example wall constructed using forms according to an embodiment of the instant application.

FIG. 7A illustrates a top view of a corner abutment of adjacent wall panel forms with reinforcements in the column according to an embodiment of the instant application.

FIG. 7B illustrates a perspective view of another embodiment of corner abutment of adjacent wall panel forms according to an embodiment of the instant application.

FIG. 7C illustrates a top view of a corner form according to an embodiment of the instant application.

FIG. 8 illustrates a perspective view of a floor or ceiling panel form according to an embodiment of the instant application.

FIG. 9 illustrates a front cross-sectional view of alignment of the respective channel segments of adjacent floor or ceiling panel forms according to an embodiment of the instant application.

FIG. 10 illustrates a front cross-sectional view of the adjacent floor or ceiling panel forms of FIG. 9 having concrete poured thereon with reinforcements and temporary support, according to an embodiment of the instant application.

FIG. 11A illustrates an alternative profile of abutting channel segments of adjacent floor or ceiling panel forms that create a beam channel according to an embodiment of the instant application.

FIG. 11B illustrates an alternative profile of abutting channel segments of adjacent floor or ceiling panel forms that create a beam channel according to an embodiment of the instant application.

FIG. 11C illustrates an alternative profile of abutting channel segments of adjacent floor or ceiling panel forms that create a beam channel according to an embodiment of the instant application.

FIG. 11D illustrates an alternative profile of abutting channel segments of adjacent floor or ceiling panel forms that create a beam channel having reinforcements and concrete thereon according to an embodiment of the instant application.

FIG. 11E illustrates an alternative profile of abutting channel segments of adjacent floor or ceiling panel forms that create a beam channel according to an embodiment of the instant application.

FIG. 12 illustrates an end view of a floor or ceiling panel form having reinforcements embedded therein according to an embodiment of the instant application.

FIG. 13 illustrates an end view of a floor or ceiling panel form having insulative material added thereto according to an embodiment of the instant application.

FIG. 14A illustrates an end view of an alternative floor or ceiling panel form according to an embodiment of the instant application.

FIG. 14B illustrates an end view of an alternative floor or ceiling panel form according to an embodiment of the instant application.

FIG. 15A illustrates an end view of an alternative floor or ceiling panel form having a utility chase therein according to an embodiment of the instant application.

FIG. 15B illustrates an end view of an alternative floor or ceiling panel form having an alternative utility chase therein according to an embodiment of the instant application.

FIG. 16A illustrates a perspective view of a beam form according to an embodiment of the instant application.

FIG. 16B illustrates a top view of the beam form in FIG. 16A according to an embodiment of the instant application.

FIG. 17 illustrates a perspective view, with portions cut away, of the beam form in FIG. 16A having reinforcements and concrete added therein according to an embodiment of the instant application.

FIG. 18A illustrates an end view of an alternative beam form according to an embodiment of the instant application.

FIG. 18B illustrates an end view of an alternative beam form according to an embodiment of the instant application.

FIG. 19A illustrates an end view of an alternative beam form having reinforcements embedded therein according to an embodiment of the instant application.

FIG. 19B illustrates an end view of an alternative beam form having an alternative reinforcement in the concrete poured therein according to an embodiment of the instant application.

FIG. 20 illustrates a perspective view of a column form according to an embodiment of the instant application.

FIG. 21 illustrates a perspective view, with portions cut away, of an alternative column form having reinforcements and concrete added therein according to an embodiment of the instant application.

FIG. 22A illustrates an end view of an alternative column form having reinforcements therein according to an embodiment of the instant application.

FIG. 22B illustrates an end view of an alternative column form having an alternative reinforcement in the concrete poured therein according to an embodiment of the instant application.

FIG. 22C illustrates an end view of an alternative column form according to an embodiment of the instant application.

FIG. 22D illustrates an end view of an alternative column form according to an embodiment of the instant application.

FIG. 22E illustrates an end view of an alternative column form according to an embodiment of the instant application.

FIG. 22F illustrates an end view of an alternative column form according to an embodiment of the instant application.

FIG. 23 illustrates a schematic of a method of constructing a structure according to an embodiment of the instant application.

DETAILED DESCRIPTION Overview

This disclosure is directed to one or more variations of a building component (also referred to hereinafter as a “form”) and a system of building components to be used together to build a structure. The building components can be implemented in new or existing structures, either entirely with other components created by the same or similar manner of manufacture (e.g., corner forms, step forms, wall panel forms, flooring forms, ceiling forms, etc.), or with conventional construction materials (e.g., wood, reinforced concrete forms, steel, drywall, etc.). Accordingly, the building components may be integrated into an existing structure either for remodeling or adding onto the existing structure, or the building components may be used to construct the entirety of a new structure.

The building components are sturdy structural forms that may be aligned and arranged together so as to form walls, floors, ceilings, etc. The forms may also be referred to as “shuttering” or “molds.” In many embodiments, individual building components include channel segments that extend along at least a portion of a perimeter of the form. Thus, by aligning the channel segments of adjacent forms, an empty channel is created therebetween. The channels extend along and between adjacent forms and, depending on the structure being built (e.g., a vertical wall vs. a horizontal floor), the channels may be completely enclosed lengthwise or may be open on a side lengthwise while being closed by the forms on an opposite side. The channels are placed and sized between forms such that reinforced concrete can be easily poured into the channels at the time of construction. As the reinforced concrete fills the channels and subsequently hardens, columns and beams of reinforced concrete are created, and the reinforced concrete bonds to the material of the forms to provide additional strength to the structure. As such, the building components (“forms”) of the instant disclosure remain a permanent part of the structure, and the poured reinforced concrete becomes integrated into the forms.

In many instances, due to the nature of the manufacture and shape of the forms, no additional framing forms are needed to hold the forms in place prior to or during the pouring of the concrete. Thus, there is no need to strip any framing forms after the concrete is poured and cured, which saves additional time and money in both labor and material costs.

The forms are generally pre-shaped for construction in the various embodiments desired using different mold frames. Thus, the forms are ready for installation upon receipt. However, inasmuch as construction designs vary significantly for myriad reasons, onsite modifications are to be expected and indeed necessary in some situations. Further, the forms are expected to carry significant loads under normal building structure standards. Accordingly, the forms may be created from a material having several desired properties. For example, in an embodiment, the building components may be created using lightweight cementious material, such as cellular concrete. Additionally, and/or alternatively, other materials may be used to create the forms, including, but not limited to: autoclaved aerated concrete (AAC), porous concrete, lightweight concrete, low-density concrete, foamcrete, insulated concrete, aircrete, polycrete, polystyrene concrete, hemperete, and potentially other light-weight non-cement-based materials. Examples of other non-cement-based materials, that may be candidates for the building components, include those materials that exhibit comparatively similar or better property characteristics as those inherent to cellular concrete. Some of the properties to consider include: fire, wind, pest, projectile resistance; insulation value for energy efficiency purposes; strength characteristics (e.g., load bearing, tensile, compression, sheer, etc.); manufacturability (e.g., curing time, difficulty level in preparation, etc.); long term durability with respect to the environment(s) in which the forms are to be installed and expected duration of use (e.g., rot and decay resistance due to moisture, bacteria, soil, sun exposure, etc.); effect of the material on the environment (e.g., toxicity to manufacturers, environment, occupants, etc.); affordability (e.g., available resources, shipping practicalities and associated costs); and ease of installation (e.g., fast erection, customizability, varied skill-level, etc.). Alternative, non-cement-based materials may include expanded polystyrene, glass-fiber reinforced gypsum, magnesium-based compounds, or other suitable material that demonstrates a high strength-to-weight ratio.

Additionally, the material of the forms may be reinforced with carbon fiber, carbon nanotubes, wire mesh, steel, or other reinforcements common to the construction industry to provide even greater load and span capabilities, as well as increase the tensile strength, manipulability, and machinability of the building components. The size, type, and quantity of reinforcements, as well as any stabilizing agents and/or organic binder(s), may vary depending on the engineering requirements for a particular building (single story, multi-story, etc.).

Moreover, in an alternative embodiment, the form includes more than two elements. For example, a form may be manufactured by casting a planar, insulative core within cellular concrete (or other material as detailed above). Such an embodiment may provide additional thermal enhancements to the panel. The insulative core may include any type of material that is thermally efficient and has a low heat transfer coefficient, as determined by those skilled in the art.

It is further contemplated to provide building components for foundations, crawlspaces, exterior walls, interior walls, shaft walls, cladding, curtains, facades, and veneers, as well as other building components such as lintels, headers, and gables. These components may be used in load bearing and non-load bearing applications. It is also envisioned that these components may be used for fencing systems such as sound barriers, privacy fencing, landscaping fencing, as well as in-fill walls, retaining walls, etc. In some embodiments, the forms may be connected together vertically or horizontally in an end-to-end or side-to-side relationship to provide a wall of a desired length for a building.

The building component system further saves time and material by combining several construction divisions into one innovative system, such as eliminating in whole or in part framing, insulation, vapor barrier, exterior sheathing, and drywall; drywall may still be installed over the panels if desired. The building component system may further minimize the requirement for extra surface coats of heavy stucco. Eliminating various construction divisions has two additional benefits immediately apparent—drastic reduction in onsite waste and the minimization of negative impact on the environment.

An additional advantage that may be achieved with the building component system is that the structures built may have high energy efficiency. This efficiency is due, at least in part, to a combination of high R-value inherent to cellular concrete, as well as thermal mass and air-tightness. The heating and cooling costs of buildings created using the instant building component system may be greatly reduced when compared to most conventional building systems.

The forms may include colors, designs, decorative finishes, textures, patterns, carvings, profiles, and other decorative elements. Furthermore, the outer faces of the forms may be produced with a highly smooth surface for improved finishing characteristics, particularly for the interior of a building, for example, to provide a finished interior wall. The forms may be manufactured to accept multiple different types of finished exterior and interior materials such as stucco, brick, rock, siding, cladding, veneers, drywall, plaster, wallpaper, paint, carpet, trim, tile, etc. In an embodiment, a paraffin coating or covering is provided on the exterior surface during manufacturing. Other coatings may be provided, such as liquid EDPM, that serve the same purpose of preventing an excessive bond between the exterior concrete wall and the bricks, as well as reduce cracking in bricks or stone due to the variations in shrinkage of the exterior concrete panel and brick or manufactured stone. This type of coating/covering may also allow for removal of a damaged brick without excessive damage to the wall panel.

Notably, the building components may easily accept screws, nails, brackets, bolts, fasteners. This feature allows for a great amount of versatility for customization in hanging cabinets, shelves, pictures, etc. Further, the building components provide furring as an integral component to the panel should additional support be desired. The furring may be wood, plastics, metal, composites, etc. The furring may provide additional anchoring support as needed to attach such things as cabinetry, shelves, fixtures, and other building components. The furring may vary in size, location, amount, and types of material, and will typically be cast into a form during the manufacturing process. In addition, fasteners similar to those used for concrete block may be utilized for heavy loads.

In yet another embodiment, a form may include one or more utility chases. A utility chase may serve as a convenient location to route utilities such as wiring, cables, piping, ventilation, etc. Receptacle boxes may also be cast into the forms, or installed on the jobsite. Chases may also serve as channels into which dowels or reinforcement bars, such as rebar, may be inserted into the forms to tie the forms into the building foundation or into other forms of the building. A utility chase may be oriented in one or more directions and positioned either near the interior concrete face, exterior concrete face, or both.

Illustrative Embodiments of a Form as a Wall Panel

In an embodiment, FIGS. 1A and 1B depict a building component, or form, of a wall panel 100. FIG. 1A depicts wall panel 100 in a vertical position for use as a vertical wall panel, and FIG. 1B depicts wall panel 100 in a horizontal position for use as a horizontal wall panel. While wall panel 100 is depicted as generally quadrangular, and particularly rectangular, wall panel 100 may be cast in other geometric shapes not depicted herein, including, for example: squares, triangles, pentagons, rhomboids, etc. Dimensions of wall panel 100 may vary depending on a builder's desires or intended use, and/or may vary depending on whether the wall panel will be installed in a vertical orientation or a horizontal orientation.

Wall panel 100 may include a panel body 102 having length “L,” a width “W,” and a thickness “t,” as shown in FIG. 1A The following description and claims may refer to a “length” direction, a “width direction,” and/or a “thickness direction,” as a reference for further defining aspects and features of wall panel 100, and similarly with other embodiments of the forms discussed herein. Furthermore, the description and claims may also define aspects or features from a perspective of looking at wall panel 100 in the direction of arrow “P,” which indicates a viewer perspective looking at a lateral side view of wall panel 100, as also shown in FIG. 1A. Accordingly, additional features of wall panel 100 are hereinafter described as explained above.

A channel segment 104 is disposed in at least one side of wall panel 100. As depicted in FIGS. 1A and 1B, however, channel segment 104 may be disposed in more than one side, and thusly may form a continuous channel segment that extends either partially or completely around a perimeter of a form. A width “W₁” of channel segment 104 may span within the thickness direction of wall panel 100 between a first side section 106 and a second side section 108. A length “L₁” of channel segment 104 may extend entirely across a side of wall panel 100 from end to end (as shown), or at least partially between the ends (not shown), along the at least one side, which side extends in either the length direction or the width direction of wall panel 100. In an embodiment where channel segment 104 extends entirely from end to end of a side (as shown in FIGS. 1A and 1B), an advantage may be realized in that, upon pouring reinforced concrete into intersecting channels (discussed further herein) and channel segments of adjacent forms, the reinforced concrete cures across joints, thereby securing adjacent forms by creating a stronger, continuous link of interconnected concrete beams and/or columns in the structure being built. Thus, the structural integrity between adjacent forms may be reinforced.

Despite the positioning of channel segment 104 between first side section 106 and second side section 108, first side section 106 and second side section 108 remain connected via a core 110. Wall panel 100 may be cast from a single material, such as a lightweight cementious material discussed above. In this case, first side section 106, second side section 108, and core 110 may be cast simultaneously. When cast simultaneously, channel segment 104 may be formed to a desired size during the casting or channel segment 104 may be cut into a solid cast wall panel as desired after casting. Additionally, and/or alternatively, wall panel 100 may be cast using multiple materials. For example, first side section 106 and/or second side section 108 may be cast from a lightweight cementious material, while core 110 may be of a different material, as detailed hereinafter with respect to FIGS. 4A and 4B.

A shape of the periphery of core 110 may correspond to the shape of the periphery of one or both of first side section 106 and second side section 108. For example, as shown in the embodiments of FIGS. 1A and 1B, the shapes of the respective peripheries of first side section 106, core 110, and second side section 108 are each rectangular. Of course, due to channel segment 104, the dimensions of the periphery of core 110 are smaller than each of the peripheries of first side section 106 and second side section 108. As such, the bounds of channel segment 104 may be defined by intersecting surfaces, namely: a surface 112 of core 110; an interior surface 114 of first side section 106 as a first portion projecting in a direction away from (e.g., transversely to) surface 112 of core 110; and an interior surface 116 of second side section 108 also projecting in a direction away from (e.g., transversely to) surface 112 of core 110. In an embodiment, one or both of surface 114 and surface 116 project (or extend) transversely to surface 112. Note, “transversely,” as used herein, may include intersecting directions of extension that differ in trajectory perpendicularly, non-perpendicularly, arcingly, or a combination thereof. For examples of the different ways surfaces 114, 116 may project transversely to surface 112, see FIGS. 3A-3C, discussed further herein.

A depth “d” of channel segment 104 may vary depending on desired or required beam or channel sizes (as discussed in detail further herein). Depth d of channel segment 104 may be varied during the manufacture of wall panel 100 by casting core 110 such that one or more of the area dimensions (e.g., width and length) of core 110 are either smaller or larger as desired, thereby exposing more or less surface area of surface 114 and surface 116. Moreover, though depicted as having a substantially uniform depth surrounding wall panel 100, depth d may further vary along the length L₁ of channel 104. For example, in an embodiment, depth d of channel segment 104 may vary with the distance from an edge of panel body 102. Thus, channel segment 104 may have a planar appearance when depth d remains substantially uniform across length L₁; or channel segment 104 may have a concave or convex appearance when depth d rises and falls or vice versa across length L₁ (not shown); or channel segment 104 may have a wavy or sinusoidal appearance when depth d rises and falls sequentially across length L₁ (not shown). Such differences in shape of channel 104 may ultimately provide different strength characteristics for loads placed thereon in the reinforced concrete poured therein (not shown in FIG. 1A or 1B).

In an embodiment, respective corresponding dimensions of first side section 106 and second side section 108 may be substantially equal or may be different. In an example where the dimensions are different, while each of first side section 106 and second side section 108 is still larger than core 110, at least one of the length or width of first side section 106 may be shorter that the corresponding at least one length and width of second side section 108. Additionally, and/or alternatively, it may be desired that a thickness of one of first side section 106 and second side section 108, at the channel segment 104, is greater or lesser than the corresponding thickness of the opposing side. (See FIG. 3A).

Note, while the following discussion regarding FIGS. 2A-5 uses distinct reference numbers for clarity with respect to the specific figures, unless stated otherwise, when the same terminology is used hereinafter as is used to describe the features of FIGS. 1A and 1B, the features are intended to be the same or significantly similar at least with respect to the functions for which they are designated. For example, wall panel 100 could be swapped for wall panel 202 and achieve the same purpose. Differences in shape, as with the profile of channel segment 104 (which appears the same as that of FIG. 3A), compared to the profile shown in FIG. 3B, may be described using the same terminology (e.g., surface, first side section, channel segment, etc.) when referring to similarly positioned features to imply the similar functions while allowing for structural variations that may enhance or otherwise alter physical properties/capabilities of the structures. Likewise, where similar features exist across the various embodiments of building components of the system disclosed herein in FIGS. 1A-22F, some of the same terminology may be used to describe features in any figures that are similar in structure and/or function.

FIG. 2A depicts the creation of a wall structure 200 implementing a pair of adjacent, aligned wall panels 202, 204. As mentioned above, when adjacent forms (e.g., wall panels 202, 204) are aligned during installation such that the respective channel segments are abutted, the abutment creates at least one of a beam channel or a column channel. In FIG. 2A, the abutment of two vertically oriented wall panels 202, 204 creates both a beam channel 206 (depicted, in part, by the dashed lines extending parallel to the upper end of wall structure 200) and a column channel 208 (depicted, in part, by the dashed vertical lines). For illustrative purposes, FIG. 2A further shows: a beam 210 of reinforced concrete extending continuously in beam channel 206 across the aligned respective channel segments of wall panels 202, 204; and a column 212 of reinforced concrete extending vertically, filling the column channel 208 formed by the aligned respective channel segments of wall panels 202, 204. The cured reinforced concrete, poured after abutment and alignment of wall panels 202, 204, bonds to both of wall panels 202, 204, thereby bonding together wall panels 202, 204 to form wall structure 200.

Additionally, FIG. 2A depicts a reinforcement member 214 extending within beam 210, a reinforcement member 216 extending within column 212, and a second column 218 (in cross-section) at a side of wall structure 200 in wall panel 204, which would abut another form (not shown) to create a complete column. Though FIGS. 2A and 2B show reinforcement members 214, 216, it is contemplated that a wall structure may be created without any reinforcement members as well.

For the sake of clarity, FIG. 2B depicts a cross-sectional view of wall structure 200 taken at line IIB-IIB in FIG. 2A. In detail, prior to pouring the reinforced concrete, the parts of wall panel 202 (e.g., a first side section 220, a second side section 222, and a core 224) are aligned, respectively, with the corresponding parts of wall panel 204 (e.g., a first side section 226, a second side section 228, and a core 230) such that channel segment 232 of wall panel 202 faces channel segment 234 of wall panel 204. More specifically, end surface 236 of first side section 220 abuts with end surface 238 of first side section 226, and end surface 240 of second side section 222 abuts with end surface 242 of second side section 228. After abutment and alignment of the forms (e.g., wall panels 202, 204), reinforced concrete may be introduced into the newly formed column channel 208 to create column 212. Reinforcement member 216 may be inserted into column channel 208 after alignment, or column channel 208 may be positioned around a previously disposed reinforcement member 216. Additionally, the seam lines that exist at the abutting surfaces 236, 238 and 240, 242 may be taped and mudded according to existing procedures, if desired.

FIG. 3A illustrates a closer side view of a profile 300A of a form, such as a wall panel, including a first side section 302 connected to a second side section 304 via a core 306. Channel segment 308 may be bounded by surface 310 of first side section 302, surface 312 of second side section 304, and surface 314 of core 306. Thus, as with the embodiment of wall panel 100 in FIG. 1A, surfaces 310, 312 project substantially perpendicularly to surface 314. Likewise, the channel segment at a lower end of wall panel 300A, is depicted as being shaped like channel segment 308. Note, a thickness “t′” of side section 302 may be substantially equal to, less than, or greater than a thickness “t″” of side section 304.

As indicated above, FIG. 3B illustrates an alternative embodiment profile 300B of a channel segment 316 of a form. Channel segment 316 is depicted as being laterally bounded by surfaces 318, 320 of a first portion of the form and a second portion of the form, respectively, each of which project away from surface 322. Surface 322 may be described as an arc or semicircular, respective ends of which intersect surfaces 318, 320. Thus, profile 300B may be defined such that surface 318 and surface 320 each arcingly transverse surface 322. For the purposes of this document, the term “arcingly transverse” refers to the intersection of two surfaces, at least one of which is not linear. Inasmuch as tangential lines through points of an arc vary in the direction of extension through the progression of the arc, the profile of a channel segment in which an arc is present, such as channel segment 316, may be defined, at least in part, as a first portion (or surface 318) projecting in a first direction and a second portion (or surface 322) projecting in a second direction that is transverse to the first direction. The first direction in which surface 318 is said to project may correspond to the direction of extension of a linear portion of the profile of surface 318, which linear portion intersects the arced surface 322. The second direction in which surface 322 is said to project may correspond to the direction of extension of a tangential line that is drawn through a point at which channel segment 316 has a greatest depth, or at any point prior to intersecting the linear portion of surface 318, at which point, the respective directions or extension would no longer be transverse but would be collinear.

FIG. 3C illustrates an alternative embodiment profile 300C of a channel segment 324 of a form. Channel segment 324 is depicted as being laterally bounded by surfaces 326, 328 of a first portion of the form and a second portion of the form, respectively, each of which project away from surface 330. Although, in the embodiment of FIG. 3C, surfaces 326, 328 are not strictly linear, the general direction of projection of the first portion and second portion of which surfaces 326, 328 are a part, respectively, remains transverse to the direction of projection of surface 330.

FIG. 3D depicts a profile 300D of a form having a channel segment 332, in which a beam 334 is formed. Further, a pair of reinforcing members 336 are shown in cross-section as dots, implying that reinforcing members 336 extend in the length direction of beam 334. A reinforcing member 338 is also depicted as extending vertically into beam 334.

FIGS. 4A-4C depict alternative embodiments of wall panels 400A, 400B, 400C. In particular, FIG. 4A illustrates wall panel 400A, having a first side section 402 attached to a second side section 404 via a core 406. Notably, core 406 is of an insulative material that is distinct from the material used to cast first side section 402 and second side section 404. Accordingly, core 406 may be inserted in a mold chamber or casting frame prior to casting first side section 402 and second side section 404 in the mold chamber so as to integrate core 406 into wall panel 400A.

In FIG. 4B, in an effort to improve strength capabilities of the forms described herein, reinforcement members 408 are embedded in wall panel 400B. In an embodiment, reinforcement members 408 be placed in a mold chamber or casting frame prior to casting wall panel 400B so as to integrate reinforcement members 408 directly throughout the form. Alternatively, reinforcement members 408 may be inserted into wall panel 400B after formation thereof. Such post formation reinforcement may be achieved by drilling holes into wall panel 400B, and subsequently inserting reinforcement members 408 into the drilled holes; or by casting holes within wall panel 400B during formation and subsequently inserting reinforcement members 408 into the precast holes.

In yet another embodiment depicted in FIG. 4C, wall panel 400C includes a core 410 that is segmented across wall panel 400C. The segmentation of core 410 provides one or more gaps 412 extending between segmented portions of core 410. As such, upon pouring reinforced concrete into the channel segment of wall panel 400C, reinforced concrete may also flow into the one or more gaps 412, thereby forming additional columns or beams and reinforcing wall panel 400C.

FIG. 5 illustrates a planar view of a wall panel 500, showing first side section 502 and core 504, as depicted via dashed lines within the perimeter of first side section 502. Wall panel 500 may also include one or more chases 506(a), 506(b), 508 cast therein at the time of formation, which may be useful for routing cabling, piping, etc. through the building structure.

FIG. 6 depicts an cross-sectional view of an example of a wall structure 600 built using a plurality of wall panels 602 (representing the depicted five, large-sized, aligned wall panels) as well as wall panel 604 (custom cut on jobsite). Each of the wall panels 602, 604 are aligned and abutted to adjacent wall panels 602, such that reinforced columns 606 (representing the depicted six, vertical concrete columns) may be cured within column channels formed vertically between adjacent panels. Additionally, beam channels may be formed in which reinforced beams 608 and 610 are formed with reinforced concrete. Note, in an embodiment as depicted in FIG. 6, there are no beam channels that run across the bottom of wall panels 602.

Illustrative Embodiments of a Form as a Corner

FIGS. 7A-7C illustrate embodiments of building components for forming a corner portion of a building structure. In an embodiment, a corner 700A may be created using similar principles as discussed above with respect to the wall panel forms, including abutment and alignment of channel segments between adjacent forms, and subsequently pouring reinforcing concrete into the beam channels and column channels created by the adjacent forms. More specifically, corner 700A may be built by aligning adjacent angled sides of wall panel 702 and wall panel 704, respectively (as shown). The angled sides may be cast as such originally, or may be cut on the jobsite at the time of installation. Wall panel 702 may have a first side section 706, a second side section 708, and a core 710. Wall panel 704 may have a first side section 712, a second side section 714, and a core 716. By leaving first side sections 706, 712 to extend further than second side sections 708, 714, and providing an complementary angled edges on the adjacent sides thereof, wall panels 702, 704 may be abutted to form an outer corner seam 718 and an inner corner seam 720. Subsequently, reinforced concrete 722 may be poured into a column channel 724, formed between the abutting channel segments of wall panels 702, 704. Further, one or more reinforcing members 726, such as rebar, may be disposed within column channel 724.

In an alternative embodiment of a corner 700B, FIG. 7B depicts wall panel 728 abutting, at a right angle, a modified wall panel 730. Wall panel 730 is modified such that corner edges of inside adjacent side sections 732, 734 are aligned, while the outer side section 736 extends beyond the dimension of opposing side section 734 of wall panel 730 to a plane parallel with outer side section 738 of wall panel 728. As such, respective channel segments of wall panels 728, 730 combine to form a column channel. In this embodiment, however, a supplemental cover 740 (e.g., panel or sheet or wood, cement, etc.) is added using fasteners 742 (e.g., screws, nails, etc.) to cover the gap between outer side section 736 of wall panel 730 and the edge of side section 738 of the unmodified wall panel 728, thereby providing a complete sidewall for the column channel, into which reinforced concrete may be poured.

In another alternative embodiment forming a corner, FIG. 7C illustrates a single piece corner form 700C. Corner form 700C may include an outside corner section connected to an inside corner section. Outside corner section may be formed with a first arm 744 a cast with and extending transversely (e.g., an angle greater than 0° and less than 180°, such as 90°) from a second arm 744 b. Inside corner section may be formed with a first arm 746 a cast with and extending transversely from a second arm 746 b. Further, first arm 744 a may be connected to first arm 746 a via a first core portion 748 a; and second arm 744 b may be connected to second arm 746 b via a second core portion 748 b, which is distinct and separate from second core portion 748 b. That is, first and second core portions 748 a, 748 b connect the outside corner section to the inside corner section and may extend only partially toward the vertex so as to leave a corner channel 750 therebetween at the vertex of the intersection of the respective arms 744 a, 744 b, 746 a, 746 b. Reinforced concrete may be poured into corner channel 750 upon installation to create a reinforced corner.

Further, in corner form 700C first and second core portions 748 a, 748 b may extend partially toward corner arm ends 752 a, 752 b, again leaving a gap so as to create channel segments 754 a, 754 b, respectively. Similar to the channel segment 104 of wall panel 100, the bounds of channel segments 754 a, 754 b may be defined by intersecting surfaces. For the sake of convenience and to avoid unnecessary repetition, the following description of the channel segments 754 a, 754 b only refer directly to reference numbers depicted at arm end 752 a of the corner form 700. However, it is contemplated that one skilled in the art will recognize that the description of the surfaces labeled in channel segment 754 a would likewise apply to channel segment 754 b. Continuing, the bounds of channel segment 754 a may be defined by: a surface 756 of core portion 748 a; an interior surface 758 of first arm 744 a as a first portion projecting in a direction away from (e.g., transversely to) surface 756 of core portion 748 a; and an interior surface 760 of first arm 746 a also projecting in a direction away from (e.g., transversely to) surface 756 of core portion 748 a. As stated above, “transversely,” as used herein, may include intersecting directions of extension that differ in trajectory perpendicularly, non-perpendicularly, arcingly, or a combination thereof.

After alignment of corner arm ends 752 a, 752 b with respective adjacent wall panels (not shown), whereby column channels are formed, reinforced concrete may be poured into channel segments 754 a, 754 b to form bonded, reinforced columns between the corner form 700 c and adjacent forms (e.g., wall panels, beam forms, etc.).

Illustrative Embodiments of a Form as a Flooring or Ceiling Panel

In FIG. 8, an embodiment of a flooring/ceiling panel form 800 is depicted. FIGS. 9-15B further depict embodiments of various aspects of flooring/ceiling panels, however, form 800 is discussed generically and the elements of form 800 apply similarly to other embodiments unless explicitly stated otherwise. Specifically, form 800 may include a body 802 having a flange 804 extending from at least one side thereof (in FIG. 8, a flange 804 extends from both sides, and see FIG. 13 for a flange that may surround the entire perimeter). Similar to wall panel 100, form 800 includes a channel segment 806. However, in form 800, flange 804 provides the foundation for channel segment 806, which when abutted with an adjacent flooring ceiling panel, forms a beam channel (discussed further herein—see FIG. 9). That is, flange 804 supports channel segment 806 having bounds that may be defined by intersecting surfaces, namely: a surface 808 of body 802; and a surface 810 of flange 804 as a portion projecting in a direction transversely from surface 808 of body 802. As above, “transversely,” as used herein, may include intersecting directions of extension that differ in trajectory perpendicularly, non-perpendicularly, arcingly, or a combination thereof.

Moreover, flange 804 has a first thickness “t′” and body 802 has a second thickness “t″” that is different than the first thickness. That is, in an embodiment, a thickness of form 800 at channel segment 806 is less than a thickness of form 800 away from channel segment 806 (i.e. at the body 802), where the thickness is defined as a distance between a front surface and a back surface opposite the front surface of form 800.

When form 800 is installed aligned and abutted with another form (e.g., another form “800”), channel segment 806 is aligned with the corresponding channel segment of the other form, such that a surface 812 of flange 804 abuts the adjacent corresponding surface. Consequently, as shown in the incomplete flooring/ceiling structure 900 of FIG. 9, a beam channel 902 forms.

By aligning surface 904 of the adjacent flange in FIG. 9 with surface 812, as depicted, the channel segment of the adjacent form faces channel segment 806 such that a surface 906 faces surface 808, and a surface 908 aligns in plane with surface 810. Thus, abutment of adjacent flooring/ceiling panels, a beam channel, such as beam channel 902, is created. During installation, reinforced concrete may be poured on the flooring/ceiling panels and into the beam channels to reinforce the structure with horizontal concrete beams.

For example, in an embodiment depicted in FIG. 10, a nozzle N may be used to deposit reinforced concrete on a flooring/ceiling structure 1000, like that shown in FIG. 9. The concrete 1002 may be poured on top of the flooring/ceiling structure 1000, which may have been further reinforced with one or more reinforcement members such as a reinforcement wire mesh 1004 and/or one or more rods of rebar 1006, which may be deposited in the beam channel as shown. As depicted, in an embodiment of the method to install a floor or ceiling using floor/ceiling panels such as form 800, a support system 1008 may be used to secure adjacent forms in position while the poured reinforced concrete cures. The support system 1008 may be of known types for similar uses in the building construction industry.

FIGS. 11A-11E depict variations of shapes of channel segments 1100 a, 1100 b, 1100 c, 1100 d, and 1100 e, respectively. In an embodiment shown in FIG. 11A, beam channel 1100 a is formed that includes a T-shaped channel. In the embodiment of FIG. 11B, beam channel 1100 b is formed and, instead of abutting only a single surface from each flange like the abutment in FIG. 9 for example, the abutment includes multiple correspondingly shaped interfacing surfaces on the adjacent flanges. Similarly, FIG. 11C depicts an alternative embodiment of abutment in beam channel 1100 c, such that one of the adjacent flanges is shaped to fit within a space formed in the other adjacent flange. In contrast, in the abutment shown in FIG. 11D, while the flanges abut in the same manner as those in FIG. 9, the portion of the forms that projects transversely to the surface of the flange is shown as projecting arcingly away. Moreover, FIG. 11D depicts how the reinforced concrete may cure on the adjacent flooring/ceiling forms. Additionally, in an alternative embodiment in FIG. 11E, the beam channels 1100 e shown are deeper so as to form even larger beams.

As seen in an embodiment shown in FIG. 12, a flooring/ceiling panel form 1200 may include, embedded with the body 1202 during casting, one or more reinforcement members such as a wire stand 1204 that is partially embedded in the form 1200 and partially exposed, for example, in the channel segment area to increase the bonding integration with the reinforced concrete to be poured thereon during installation. Additionally, and/or alternatively, a wire mesh 1206 may be embedded within the body 1202.

FIG. 13 depicts an embodiment of a flooring/ceiling panel form 1300 including a body 1302 on which is layered an insulative member 1304. The types of materials that would be considered to be insulative members may be known to those skilled in the art. The insulative member 1304 may be added after casting and curing form 1300 or may be added during or after casting but prior to curing form 1300 so as to integrate insulative member 1304 more thoroughly. Moreover, insulative member 1304 may be placed to surround form 1300 along the flange 1306 thereof (particularly when form 1300 includes a flange 1306 extending along all sides thereof), or may be layered otherwise (not shown). Additionally, as indicated by dashed lines, insulative member 1304 may include one or more holes 1308 to further integrate the reinforced concrete when introduced during installation, or for lightweight cementious material during casting form 1300.

In other embodiments seen in FIGS. 14A and 14B, a flooring/ceiling panel form may be modified for reinforcement, before or after casting, to include one or more mid-body beam channels, which may extend in the same direction as the beam channels created between adjacent forms, and/or may extend in a direction that is transverse to the direction of extension of the beam channels created between adjacent forms. For example, in FIG. 14A, a flooring/ceiling structure 1400A using a form with a body 1402A may include one or more mid-body beam channels 1404A (only one depicted). Beam channels 1406 may be formed as previously described above by abutment of respective channel segments of adjacent forms. Similarly, in form 1400B of FIG. 14B, a body 1402B may include one or more mid-body beam channels 1404B (two depicted). An additional difference between body 1402A and body 1402B is that body 1402B has a variation of the side structure that eliminates the channel segments seen in body 1402A. Specifically, a first side 1408 of body 1402B includes an overhanging ledge portion 1410, which when abutting an adjacent form, is shaped to correspond and engage with a wall 1414 shaped to interlock with the ledge portion 1410, such as the shape of a second side 1412 shown in FIG. 14B. Therefore, the abutment of either of first side 1408 or second side 112 with the corresponding engagement side of an adjacent form eliminates a beam channel between the adjacent forms. However, mid-body beam channels 1404B may provide additional strength reinforcement properties for the flooring/ceiling structure.

In FIGS. 15A-15B, flooring/ceiling panel forms 1500A and 1500B each depict an embodiment of a possible chase structure, useful for running cables, piping, etc. through the building structure. In an embodiment of FIG. 15A, a body 1502A of form 1500A may include a through hole for a chase 1504A that extends through a length or a width of body 1502. Chase 1504A may be created when form 1500A is cast or bored out thereafter, for example at the jobsite prior to or during installation, if necessary. In an embodiment of FIG. 15B, a body 1502B may include an enclosable cavity as a chase 1504B. A cover 1506 may be created to removably enclose chase 1504B, and may be secured via fasteners (not shown), press fit, interference fit, surface friction fit, etc. While cover 1506 is depicted as enclosing chase 1504B in an inset position that is offset from a plane of the lower surface of form 1500B such that the plane of the cover is flush the plane of the lower surface, it is contemplated that a cover may enclose a chase in a manner that does not create a planar surface, as desired, and such a cover may be fastened in any suitable manner.

Note, despite different aspects or features being described and shown in distinct figures herein, it is contemplated that several features, though depicted herein in different figures for clarity, may be implemented within a single form without departing from the intended scope of protection for this disclosure. For example, a single flooring/ceiling panel form may include an insulative member, reinforcement members, a chase, and a mid-body beam channel. This same principle of using a variety of features in a single form may apply through any of the various building components described herein, such as the wall panel form, the corner form, the beam form, the column form, etc.

Illustrative Embodiments of a Form as a Beam Form

FIG. 16A depicts a beam form 1600 in perspective view. For the sake of clarity and convenience, FIG. 16B depicts the same beam form 1600 in top planar view. Accordingly, reference numbers discussed with respect to FIG. 16A equally apply to FIG. 16B.

Beam form 1600 includes a channel segment 1602 that is supported by opposing sidewalls 1604, 1606 extending from base wall 1608. As with channel segment 104 of wall panel 100, channel segment 1602 may be defined similarly by the surfaces that provide the boundaries for a beam channel of reinforced concrete integrated with beam form 1600 upon installation. That is, channel segment 1602 may be defined by intersecting surfaces, namely: a surface 1610 of base wall 1608; an interior surface 1612 of sidewall 1604 as a first portion projecting in a direction away from (e.g., transversely to) surface 1610 of base wall 1608; and an interior surface 1614 of sidewall 1606 also projecting in a direction away from (e.g., transversely to) surface 1610 of base wall 1608. In an embodiment, one or both of surface 1612 and surface 1614 project (or extend) transversely to surface 1610. Note, “transversely,” as explained above, may include intersecting directions of extension that differ in trajectory perpendicularly, non-perpendicularly, arcingly, or a combination thereof. Thus, beam form 1600 includes a first side that is convex and a second side that is concave, and the channel segment 1602 extends along the concave second side.

Inasmuch as beam form 1600 may be combined consecutively with additional beam forms (not shown), beam segment 1602 may itself form a portion of the installed “beam channel,” or, in a case where beam form 1600 is long enough for use in a space by itself (without aligning with other beam forms), reference number 1602 may be referred to as simply the “beam channel” since it is not merely a “segment” of the ultimate channel.

FIG. 17 merely depicts a prospective view of a beam 1700, with a partial cut-away portion, to view internal features clearly. Beam 1700 may include beam form 1600 with reinforced concrete 1702 and reinforcement members 1704 filling the beam channel segment.

FIGS. 18A and 18B depict alternative embodiments and profiles of beam forms. In an embodiment in FIG. 18A, a beam form 1800A may include a pair of opposing L-shaped sections 1802, 1804 that create the channel segment (discussed above) by abutting corresponding surfaces 1806 and 1808 of section 1802 and section 1804, respectively, as depicted. That is, an edge of one arm of the L-shape for each section 1802, 1804 is aligned and abutted to form the channel segment/channel into which reinforced concrete may be poured. FIG. 18B depicts a single-piece beam form 1800B similar to beam form 1600, only having an I-beam type contour profile on the interior surfaces of the channel segment.

In FIG. 19A, an embodiment of a beam form 1900A may include one or more reinforcement members 1902A within the channel segment, on or partially embedded therein (as depicted). Similarly, FIG. 19B depicts another embodiment of a beam form 1900B in which concrete has already been poured, and in which is another embodiment of a reinforcement member 1902B. It is noted that though FIGS. 19A and 19B depict an end view of beam forms 1900A, 1900B, it is implied that the respective reinforcement members 1902A and 1902B may extend entirely or at least partially along a length direction of beam forms 1900A and 1900B, respectively.

Illustrative Embodiments of a Form as a Column Form

Illustrated in FIG. 20 is an assembled column 2000. Column 2000 may be formed via a first column form 2002 aligned with and abutting a second column form 2004. First column form 2002 includes a channel segment 2006 that may be aligned with a channel segment 2008 of second column form 2004 to create a column channel 2010. Thus, both of the first and second column forms 2002, 2004 include a first side that is convex and a second side that is concave, and the channel segments 2006, 2008 extend along the respective concave second sides. Inasmuch as the abutment and alignment of the projecting portions of the forms extending transversely from a base surface to create a channel has been described in detail above for similarly structured channels (e.g., where two adjacent forms are involved, such as with the column channel 208 between wall panel 202 and wall panel 204 depicted in FIG. 2B), further details of the abutment of first column form 2002 and second column form 2004 (or any of the other embodiments of a column form herein, unless explicitly stated) are not described in detail herein.

FIG. 21 depicts a perspective view with a partial cut-away portion of an embodiment of a column 2100 having a first column form 2102 aligned and abutting a second column form 2104. Prior to pouring reinforced concrete 2106, a user may wrap a strap 2108 around the abutted first and second column forms 2102, 2104, or the user may other suitable means to secure the first and second column forms 2102, 2104 in abutment. Note, FIG. 21 further depicts a reinforcement member 2110 disposed within column 2100. Further, it is noted that column 2100 has a different external shape than column 2000, (i.e., quadrangular instead of cylindrical), and that it is contemplated that various shapes may be used, which may still be within the scope of the protection afforded by this disclosure.

FIGS. 22A-22F depict top views of various alternative embodiments of column channels 2200A, 2200B, 2200C, 2200D, 2200E, 2200F. For example, FIG. 22A depicts a column channel 2200A having a first column form 2202 that is planar and sized to cover the open side of a three-walled, second column form 2204. Column channel 2200A further depicts reinforcement members 2206, part of which may be embedded within the wall(s) of second column form 2204. In another example, FIG. 22D depicts an embodiment of a column channel 2200D that includes an I-shaped channel profile 2208. The column channel 2200E in FIG. 22E is an embodiment having four similarly shaped channel segment pieces 2210 a, 2210 b, 2210 c, 2210 d, which fit together abuttingly to form column channel 2200E. Finally, FIG. 22F depicts a column channel 2200F that includes a feature 2212, which in an embodiment may be a hole for a chase, or alternatively may be a position for a reinforcement member in the wall of column channel 2200F.

Illustrative Embodiment of a Method of Constructing a Building with Forms

FIG. 23 Illustrates a flowchart of a method 2300 of constructing a building structure. Method 2300 may include acts such as act 2302, in which a form is disposed in a position for constructing a portion of a structure. The form may be pre-shaped and made of a lightweight cementious material. Further, the form may include a channel segment that is defined, at least in part, by a base region and a wall that extends from the base region. In act 2304, a corresponding form having a corresponding channel segment may be abutted against the form such that: the channel segment and the corresponding channel segment are aligned, and at least one of a beam channel or a column channel is created between the form and the corresponding form.

Method 2302 may continue with act 2306, in which a structural reinforcement member may be aligned with at least one of the form or the corresponding form, or within the at least one of the beam channel or the column channel. In act 2308, a reinforced concrete mix may be poured into the at least one of the beam channel or the column channel such that the form and the corresponding form become a permanent fixture with the reinforced concrete upon curing. Additionally, the method 2310 may include arranging the form and the corresponding form to create one of a wall, a support column, or a support beam of the building structure.

CONCLUSION

Although several embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the claims are not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the claimed subject matter. 

1. A building component, comprising: a form that is pre-shaped and made of a lightweight cementious material, the form having a channel segment that extends along at least a part of the form, a profile of the channel segment being defined, at least in part, by a first portion that projects in a first direction and a second portion that projects in a second direction that is transverse to the first direction, and the profile of the channel segment being defined from a perspective of looking at the channel segment in line with a direction of extension of the at least one channel segment, wherein the form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment, the abutment being between the channel segment and the corresponding channel segment such that at least one of a beam channel or a column channel is created between the form and the corresponding form.
 2. The building component according to claim 1, wherein the channel segment surrounds at least a portion of an outer perimeter of the form.
 3. The building component according to claim 1, wherein a thickness of the form at the channel segment is less than a thickness of the form away from the channel segment, the thickness being defined as a distance between a front surface and a back surface opposite the front surface.
 4. The building component according to claim 1, wherein a thickness of the form is substantially uniform across an entirety of the form, the thickness being defined as a distance between a front surface and a back surface opposite the front surface.
 5. The building component according to claim 4, wherein the channel segment is disposed into peripheral edges of the form between the front surface and the back surface.
 6. The building component according to claim 1, wherein the cross-section of the channel segment is further defined by a third portion that projects in the first direction in parallel with the first portion.
 7. The building component according to claim 1, wherein the channel segment is a first channel segment, and wherein the form further includes a second channel segment that extends in a direction orthogonal to a direction of extension of the first channel segment.
 8. The building component according to claim 1, further comprising a structural reinforcement member engaged with the form.
 9. The building component according to claim 8, wherein the structural reinforcement member includes one or more of: rebar, wire mesh, carbon fiber, or one or more dowels.
 10. The building component according to claim 8, wherein the structural reinforcement member is embedded, at least in part, within the form.
 11. A building component, comprising: a form that is pre-shaped, the form including a channel segment, defined, at least in part, by a base region and a wall that extends from the base region, wherein the form is configured for installation as a permanent fixture in a building structure by abutment of the form with a corresponding form having a corresponding channel segment, the abutment being between the channel segment and the corresponding channel segment, and wherein: when respective ends of the respective base regions of the channel segment and the corresponding channel segment are in abutment, a beam channel is created between the form and the corresponding form, and when respective ends of the respective walls of the channel segment and the corresponding channel segment are in abutment, a column channel is created between the form and the corresponding form, and wherein the form is made of a lightweight cementious material having a composition that provides a chemical and/or physical property such that, upon pouring and setting of a reinforced concrete mix into the beam channel or the column channel, the form bonds irreversibly to the reinforced concrete mix.
 12. The building component according to claim 11, wherein the wall of the channel segment is a first wall, the first wall extending from a first side of the base region, and wherein the channel segment is further defined by a second wall that extends from a second side of the base region, the second side being opposite the first side.
 13. The building component according to claim 11, wherein the form is a substantially planar panel, and the channel segment extends along at least a portion of a perimeter of the form.
 14. The building component according to claim 11, wherein the form has a first side that is convex and a second side that is concave, and the channel segment extends along the concave second side.
 15. (canceled)
 16. The building component according to claim 11, wherein the form includes a chase to accommodate wiring in the building structure.
 17. A method of constructing a building structure, the method comprising: disposing a form in a position for constructing a portion of the building structure, the form being pre-shaped and made of a lightweight cementious material, and the form including a channel segment, defined, at least in part, by a base region and a wall that extends from the base region; abutting a corresponding form having a corresponding channel segment against the form such that: the channel segment and the corresponding channel segment are aligned, and at least one of a beam channel or a column channel is created between the form and the corresponding form; and pouring a reinforced concrete mix into the at least one of the beam channel or the column channel such that the form and the corresponding form are a permanent fixture with the reinforced concrete.
 18. The method according to claim 17, further comprising aligning a structural reinforcement member with at least one of the form or the corresponding form.
 19. The method according to claim 17, further comprising aligning a structural reinforcement member within the at least one of the beam channel or the column channel.
 20. The method according to claim 17, further comprising arranging the form and the corresponding form to create one of a wall, a support column, or a support beam of the building structure. 